Communication Basics

Topics
ISO OSI Layers Sajan Joseph
RS 232, 485 Sajan Joseph
HART Sajan Joseph
Modbus RTU Lalit Varshney
Ethernet Lalit Varshney



The problem with communication ... is the illusion that it has been accomplished.
G.B. Shaw
ISO OSI 7 Layer Model
People Don't Need This Stuff Presented Anyway
ENCAPSULATION
Open Systems Interconnection Model
Describes how information from a software application in
one computer moves through a network to a software
Application in another computer.
Application Layer
E.g.:- HTTP, SMTP, FTP
Presentation Layer
Standard formats (GIF, TIFF, MPEG), Data
Compression, Data conversion to ASCII, EBCDIC
Session Layer
Establish, Manage, Terminate sessions

Transport Layer
Segmenting of data, data sequencing, flow control.
E.g.:- TCP
Network Layer
Defines network Addresses (E.g.:-IP address)
Opens shortest path, keep track of number of hops
Data Link Layer
Media Access Control (MAC Address) , Error
notification
Physical Layer
Defines voltage levels, baud rates etc. E.g.:- Network
interface cards.


Serial Communication - Terms
Balanced vs. Unbalanced Standards
Unbalanced - An unbalanced signal is represented by a single signal wire
where a voltage level on that one wire is used to transmit/receive binary 1
and 0.
Balanced - A balanced signal is represented by a pair of wires where a
voltage difference is used to transmit/receive binary information
Simplex, Half Duplex, Full Duplex
Simplex - A simplex system is one that is designed for sending messages in one direction only.
Half-Duplex - Half duplex communications occurs when data flows in both directions; although in only one
direction at a time.
Full-Duplex - In a full duplex system, the data can flow in both directions simultaneously.

RS-232 Serial Communication
Interfaces between Date Terminal Equipment (DTE) and a Data Communication Equipment (DCE).
E.g.:- Communication between a Computer (DTE) and a Modem (DCE)
RS stands for Recommended Standard
Characteristics
Point to Point
Unbalanced Low noise immunity
Full Duplex
Available in 9 Pin or 25 Pin configurations


Disadvantages
Max. speed of transmission 19.2 Kbps
Susceptible to noise
Distance Limitation 50 ft.
Multi drop is not possible
RS-485 Serial Communication
Characteristics
Multi-drop
Balanced High noise immunity
Half-Duplex or Full Duplex
2 wire or 4 wire twisted pair cable
Max. number of devices on the
network 32
Distances Up to 1200m
Speeds Up to 100Kbps
Even though RS-485 is available in both 2-wire and 4-
wire configurations, 2-wire is more common.
RS 485 2-wire configuration is Half Duplex, whereas 4
wire configuration is Full Duplex.
HART Communication
HART Highway Addressable Remote Transducer
HART is a master-slave communication protocol, which means that during
normal operation, each slave (transmitters, actuators) communication is
initiated by a master (DCS, PLC) communication device.
Based on the Bell 202 telephone communication standard
Operates using the frequency shift keying (FSK) principle
The digital signal is made up of two frequencies 1,200 Hz and 2,200 Hz
representing bits 1 and 0, respectively. Sine waves of these two
frequencies are superimposed on the direct current (dc) analog signal
cables to provide simultaneous analog and digital communications.
Because the average value of the FSK signal is always zero, the 420 mA
analog signal is not affected. The digital communication signal has a
response time of approximately 23 data updates per second without
interrupting the analog signal. A min. loop impedance of 230 Ohms is
required for communication.
Each HART device has a 38-bit unique address encoded at the
time of manufacture that consists of the manufacturer ID code,
device type code, and device-unique identifier. A HART master
must know the address of a field device in order to communicate
with it.

HART Communication
Benefits - The traditional 420 mA signal is used to communicate one process variable, while additional process
variables, configuration parameters, and other device data are transferred digitally using the HART protocol. The HART
communication digital signal gives access to secondary variables and other data that can be used for maintenance, and
diagnostic purposes. Backward compatibility of HART ensures that investments in existing cabling and current control
strategies will remain secure.
MODBUS
PROTOCOL
The Modbus protocol
Modbus is an application layer messaging protocol
developed by Modicon in 1979, positioned at level 7
of the OSI model that provides client/server
communication between devices connected on
different types of buses or networks.

Modbus is a request/reply protocol and offers
services specified by function codes. Modbus function
codes are elements of Modbus request/reply PDUs
(Protocol Data Unit).

RS-232 VS RS-485
The original Modbus interface ran on RS-232,
but most later Modbus implementations used
RS-485 because it allowed longer distances,
higher speeds and the possibility of a true multi-
drop network. In a short time hundreds of
vendors implemented the Modbus messaging
system in their devices and Modbus became the
de facto standard for industrial communication
networks.

Serial Transmission Modes
ASCII / RTU
Serial Modbus connections can use two basic transmission modes,
ASCII or RTU, remote terminal unit. The transmission mode in serial
communications defines the way the Modbus messages are coded.
With Modbus/ASCII, the messages are in a readable ASCII format.
The Modbus/RTU format uses binary coding which makes the
message unreadable when monitoring, but reduces the size of each
message which allows for more data exchange in the same time
span. All nodes on one Modbus network segment must use the same
serial transmission mode. A device configured to use Modbus/ASCII
cannot understand messages in Modbus/RTU and vice versa

Modbus RTU is an open, serial (RS-232 or RS-485) protocol based
on master/slave or client/server architecture. It is popular, well
established, relatively easy to implement and reliable. Since it is so
easy to implement, Modbus RTU has gained wide market
acceptance wherever Industrial Automation Systems (IAS) or
Building Management Systems (BMS) need to communicate with
other devices. In fact, Modbus RTU is probably the most
implemented automation protocol of all, and a quick search of Google
will confirm this.
Modbus Addresses
Legal Modbus RTU node addresses are 1-254. 0 is
reserved for broadcast messages, and useable for writes
only. This is very seldom used since there is no
confirmation that the message was successfully received at
the server node. If the physical layer is RS-232 then only
one node can be implemented anyway. The RS-485
specification limits the number of nodes to 32, although
some RS-485 drivers will allow this limit to be extended
somewhat.

Device address Description
1...10000 Coils
10001...20000 Inputs
3000140000 Input Registers
40001...50000 Holding Registers

Modbus Configuration Examples
with Delta V DCS system
Modbus Configuration Examples
with Delta V DCS system
Modbus Configuration Examples
with Delta V DCS system
Modbus Configuration Examples
with Delta V DCS system
Modbus Configuration Examples
with Delta V DCS system
Modbus Configuration Examples
with Delta V DCS system
Modbus Data Port(s) Settings
Media RS485
Protocol Modbus RTU
Communications (Half Duplex: 2-wire) - [Full: 4-wire] 2-wire
Serial Cable Connector Type (PLC: 9 PIN male?) 9 PIN female
Slave or Device ID 1
Data Bits 8
Stop Bits 1
Baud Rate 19200
Parity No Parity
Modbus Configuration Examples
with Delta V DCS system
Communications (Pin Numbers)
DCS
Description
PLC
[ 2 ] DATA (+) BLACK
[ ? ]
[ 4 ] DATA (-) RED
[ ? ]
[ 1 ] Shield

Ethernet
Most widely deployed LAN technology
60% + of all LAN installations
Most common office automation LAN
Will encounter in a variety of applications including plant LANs, sub-networks, and
as a vehicle for control device connection
Inexpensive
Widely understood
Excellent migration path to future technologies
Fast ethernet
Gigabit ethernet
Most typically LANs complying to IEEE 802.3 CSMA/CD specification; there are slight
differences between ethernet at IEEE 802.3
Ethernet
Ethernet is a contention LAN -- CSMA/CD
access -- although typically fast -- is not guaranteed
this performance profile is well suited to file transfer applications
CSMA/ CD imposes minimal controls, allows fast access, and provides collision
detection and resolution mechanisms
Four (4) implementations:
10base-T - twisted pair media via hub connection
10base-2 - thin coaxial cable media
10base-5 - thick coaxial cable media
10base-FL - fiber optic media
Ovation will integrate/ interface to ethernet as follows:
Printer support - either via a bridge or via a sub-net
PLC integration - either via a bridge or via a controller sub-net
Plant LAN integration
Ethernet
10base-T
UTP media
Star topology
Most common implementation
RJ-45 cable connection
Connection via hub
One (1) device per hub port
Hub isolates individual end stations
from the main network
Maximum of 100 meters per segment -
installation can span 200 meter
diameter without repeaters
Variety of hub features and capabilities
HUB
Ethernet
10base-2
Coaxial cable
Bus architecture
Passive tap connection
200 meters max segment length
32 devices per segment
Station connection may require a
transceiver or media converter
NIC may support 10base-T and
10base-2
Network span can be increased
through the use of repeaters
Transceiver and drop cable
BNC T Connector
BNC T Connector on
NIC 10base-2 port
Ethernet
10base-5
Thick coax media
Bus topology
Typically backbone implementation
500 meters max segment length
100 devices per segment
Station requires transceiver for
connection -- typically vampire taps
AUI on NIC is transceiver connection

Fast Ethernet
100 Mbps extension of ethernet
Logical extension of 10 Mbps ethernet
Provides an excellent migration path to higher performance
Retains CSMA/CD
No impact on higher level protocols or applications
Backbone application is typical
10/100 auto-sensing NICs available
10 times the bandwidth at twice the price of 10 Mbps
Fiber and UTP media support
Due to higher speed has a smaller application radius than 10 Mbps ethernet
Implementations:
100baseT4 - four (4) pairs of Category 3,4,or 5 UTP
100base-TX - two (2) pairs of Category 5 UTP or STP
100base-FX - two (2) strands of 62.5/125 multi-mode fiber
Ethernet Application Example
Localized Ethernet information highway
Westations
Westnet II data highway
Hub - Provides physical connection for
printer and Westations via UTP.
Printer - Communicates with Westations via UTP
HUB connection.
UTP cables, hub, Westation on-board
ethernet controllers, and printer on board
ethernet controller constitute information
highway implementation...
10baseT application using hub and UTP - for segment length less than 100 meters
Ethernet Application Example
10base-T connected via fiber optic cable
Westations
Westnet II data highway
Printer
Fiber optic segment linking two hubs and connected equipment
Use of fiber optics assumes separation of >500 meters and/ or
high electrical noise environment. Media conversion from local
UTP to fiber accomplished in the hub
Printers are ethernet-based via hub connection and integral ethernet controller.
Network configuration allows any Westation to direct print output to either
printer.
Westations
Westnet II data highway
Hub
Printer
Media Conversion
in Hub
Westations
Westnet II data highway
Printer
Fiber optic segment linking two hubs and connected equipment
Use of fiber optics assumes separation of >500 meters and/ or
high electrical noise environment. Conversion from local
UTP to fiber accomplished using a media converter
Westations
Westnet II data highway
Printer
Media converter Media converter
UTP
UTP
Media Conversion
with external
converters
Hub
Hub
Hub